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Keywords: This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any
part of this document may be disclosed to others or reproduced, stored in a retrieval system, or transmitted in
any form by any means (electronic, mechanical, reprographic recording or otherwise) without prior written
consent of the owner.
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TABLE OF CONTENTS
i Document Authorisation................................................................................................................... 3
ii Revision History ............................................................................................................................... 3
iii Related Business Processes ........................................................................................................... 4
iv Related Corporate Management Frame Work (CMF) Documents .................................................. 4
1 Introduction ...................................................................................................................................... 7
1.1 Purpose ...................................................................................................................................... 7
2 Scope ............................................................................................................................................... 7
2.1 Changes to the Specification ..................................................................................................... 7
2.2 Review and Improvement .......................................................................................................... 7
2.3 Specification Owner's Responsibility ......................................................................................... 8
2.4 Effective period .......................................................................................................................... 8
3 Abbreviated terms and definitions ................................................................................................... 8
3.1 Abbreviated terms ...................................................................................................................... 8
3.2 Definitions .................................................................................................................................. 9
4 Material requirements ...................................................................................................................... 9
4.1 Raw Material Suppliers .............................................................................................................. 9
4.2 Chemical composition ................................................................................................................ 9
4.3 Line pipe ................................................................................................................................... 10
4.4 Pressure vessels/ heat exchangers/ air coolers ...................................................................... 10
4.4.1 Chemical Composition ........................................................................................... 10
4.4.2 Mechanical Properties ............................................................................................ 11
4.4.3 Examinations .......................................................................................................... 11
4.4.4 Post Weld Heat Treatment ..................................................................................... 12
4.4.5 Manufacturing Process........................................................................................... 12
4.4.6 Heat Treatment ...................................................................................................... 12
4.5 Clad/weld overlay ..................................................................................................................... 12
5 HIC testing additional requirements............................................................................................... 12
5.1 Testing Laboratories requirements .......................................................................................... 12
5.2 Retesting .................................................................................................................................. 13
5.3 HIC testing Acceptance criteria ................................................................................................ 13
5.4 Pressure vessels ...................................................................................................................... 13
The following minimum acceptance criteria for HIC for sour service vessels shall apply. ................ 13
5.5 Pipeline steel ............................................................................................................................ 13
5.6 On-plot Piping and fittings ........................................................................................................ 14
6 SSC testing of carbon and low alloy steels ................................................................................... 14
6.1 Acceptance criteria:.................................................................................................................. 14
6.2 SOHIC and SZC testing ........................................................................................................... 14
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1 Introduction
1.1 Purpose
The purpose of this specification is to define additional requirements to other company
specifications (SPs), Shell DEPs and MESC SPEs, and International Standards for materials in
SOUR service environments. This specification also addresses some of the roles and
responsibilities of projects, function, designers, contractors and vendors to ensure materials are
designed, manufactured, procured and constructed to meet Company specified technical
requirements within agreed delivery period.
This Specification is intended for use by Petroleum Development Oman LLC (PDO), its
Contactors/Subcontractors and Design Consultants and vendors for all PDO equipment and
facilities, some of the equipments are covered below:
a) Pressure vessels/ Heat exchangers/ Air coolers
b) Pipelines/flowlines/ pig launcher/ receiver and manifolds
c) Compressors
d) Pumps
e) Storage tanks
f) Field instrumentation
g) On plot piping components
h) Well completion
2 Scope
This specification shall be applied in addition to other Company, Shell and international technical
specifications for all materials used in sour service environment as defined in DEP 30.10.02.15-
Gen and ISO 15156.
This specification shall be read in conjunction with other Company, Shell and International
Technical Specifications such as DEP 39.01.10.11-Gen, 39.01.10.12-Gen, DEP 31.22.00.31-
Gen, DEP 31.40.20.37-Gen, DEP 30.10.02.15-Gen, DEP 30.10.02.16-Gen, NACE TM0284;
NACE TM0177 and ISO 15156-1/2/3.
This specification is intended to cover H2S related environmental cracking mechanisms
SSC,SOHIC,SWC/HIC, CSCC, and not intended to cover other threats caused by H2S
environments such as pitting, crevice or general corrosion.
In case of any conflict between this specification and other standards the most stringent
requirements shall apply.
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3.2 Definitions
Company : Petroleum Development Oman LLC (PDO).
Shall : Indicates the requirement
Should : Indicates the recommendation
SHALL [PS] : Indicates a process safety requirement
4 Material requirements
The definition of sour service shall be as stated in 3.19 of ISO 15156-1 as indicated by DEP
Specification 30.10.02.15-Gen.
Therefore the requirements of this specification, and DEP Specification 30.10.02.15-Gen, shall
be applied when design estimates, or measured operating conditions, identify any level of H 2S
above detectable limits. Unless explicitly specified, the permitted exclusions of Table 1 in ISO
15156-2 and ISO 15156-3 shall not be applied.
HIC testing shall apply to all product forms of carbon steel system components when specified
in the applicable manufacturing or supply standard. Where HIC testing is left optional (not
specified in the product specification), supplementary HIC testing shall be carried out when a
risk assessment results in a medium or high risk ranking within the PDO risk assessment matrix
as per the following criteria:
- Likelihood rating of B and a consequence rating developed from a loss of containment
through a 25 mm hole (a medium hole as described in DNV-RP-G101) in the particular
item.
For carbon steel equipment operating continuously above 65ºC HIC testing is not required.
Design documents shall identify the service conditions as “Sour” or “Non Sour”. “Sour Service”
shall be specified in the Purchase requisition/ ITP, Manufacturing procedure.
Carbon steel shall be designed and manufactured from the melting, casting and mechanical
working stage to meet the sour service and HIC requirements by controlling the chemistry and
microstructure. Original materials (Mill) MTC shall indicate materials compliance with sour
service and HIC testing.
Clause A.2 of ISO 15156-2 shall apply to all carbon steel items designated as being in “Sour
Service.” SSC Regions of ISO 15156-2 shall not be applied.
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2. The micro-alloying elements boron (B), titanium (Ti), niobium (Nb) and vanadium (V)
shall not be intentionally added to the steel, unless the Principal has given prior
approval. Chemical analysis results and carbon equivalent shall be reported in a
material test report (MTR).
4.4.3 Examinations
All plate shall be subjected to an ultrasonic lamination check in accordance with EN 10160,
quality classes S2 (plate) E3 (Edge), or ASME SA-578, acceptance Level A, (ASME SA-578
Supplementary requirement S1 shall be applied) or JB 4730, whichever specification is applied.
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HIC testing shall be carried out as per DEP 30.10.02.16-Gen with following additional
requirements:
a. All HIC tests shall include a control sample. The control sample after testing shall
exhibit minimum Average Crack Length Ratio (CLR) of 20%. If the controlled sample
fails to meet this requirement the test shall be deemed as failed.
After testing, each specimen section shall be polished metallographically as per ASTM E3 and
etched if required as per ASTM E407 for evaluation.
Extreme care shall be taken not to contaminate the specimens. They shall be handled using
only degreased tongs or clean gloves. Specimens shall not be coated in any way before
exposure to environment.
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5.2 Retesting
Retesting of the failed heat shall not be permitted. The failed heat shall be rejected.
For line pipe manufacturing, when a heat has failed HIC test as part of quality control program,
testing of two additional heats (one before and one after the failed heat) shall be carried out.
Both of these heats shall pass the HIC test. If one or both of these tests fail the previous ten
heats shall be tested and only passed tests shall be accepted.
The following minimum acceptance criteria for HIC for sour service vessels shall apply.
Table 2: Acceptance criteria sour service shall be as follows:
% maximum)
CLR CTR CSR
Average per specimen 15 5 2
The maximum individual crack length on any section shall not exceed 5 mm.
If any specimen fails to meet any of the above acceptance criteria, the heat of steel
represented by the test shall be rejected.
For vessels operating with H2S in the gas above 5 %, the following acceptable criteria shall be
considered.
Table 3: Acceptance criteria wet conditions, >5 % of H2S in gas phase.
% maximum)
CLR CTR CSR
Average per specimen 10 3 1
Single 12 4 1.5
The maximum individual crack length on any section shall not exceed 5 mm.
If any specimen fails to meet any of the above acceptance criteria, the heat of steel represented
by the test shall be rejected.
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Welded sections shall be tested by FPB except longitudinal welds in pipes with ≤6” ND where CR
tests are applicable.
Test Temperature: The temperature shall be maintained at ambient (24 deg C ± 3 deg C) as this
is the “worst case” expected in service for the occurrence of SSC in carbon and low alloy steels.
UT : Uniaxial Tensile test in accordance with NACE TM0177-05, Method A
FPB: Four Point Bend test is in accordance with EFC Publication 16, Appendix 2
CR : C-ring test in accordance with NACE TM0177-05, Method C
AYS : Actual Yield Stress
ND: Nominal Diameter
CRA materials designed to operate outside the envelop specified in DEP 39.01.10.12-Gen or
DEP 30.10.02.15-Gen shall be subjected to two different SSC/SCC tests including SSRT/RSRT
test in accordance with Annex B of DEP 30.10.02.15-gen. and NACE TM0177, EFC 17 and
ISO15156-3.
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Scope of work for SSC/SCC testing shall be reviewed and approved by function Company
Materials & Corrosion Engineer CFDH prior to placement of the order.
8 Quality Management
All equipment / components intended for sour service shall be manufactured and constructed to
meet the requirements of ISO 29001. ITP requirements shall be stated in the purchase
specification. For “Sour Service,” ITP shall be in place and the company/ TPI interventions
(witness/ review and monitoring stages) as per the equipment criticality rating.
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b. All the first day production test reports for line pipe shall be submitted within the 14
days from the start date of production and shall be approved by a Materials and
Corrosion Engineer TA 2.
Contractor/Manufacturer
Prepare project specific specification including HIC/SSC/SOHIC/SZC testing
requirements, acceptance criteria and as part of purchase requisitions and obtain
approval from the Company Function Materials and Corrosion Engineer TA2
TPI to review the laboratory certification approval covers the testing scope.
TPI Shall not deviate from the Company approved Inspection & Test Plans (ITP) without
formal written approval from Company Function/Quality Assurance CFDH.
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10 Appendix 2: References
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Comments:
Suggestions:
Recd.: To CFDH:
CFDH Actions
Recd. Decision: Inits.: Ref. Date:
Date: Reject: Ind.:
Accept, revise at next issue:
Accept, issue temporary amendment
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Comments:
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